Wheel and method of making the same



May 31, 1966 s. F. wATANABE ETAL 3,253,862

WHEEL AND METHOD OF MAKING THE SAME 2 Sheets-Sheet l Filed June 8, 1964 May 31, 1966 s. F. wA-rANABE ETAL 3,253,862

WHEEL AND METHOD OF MAKING THE SAME 2 Sheets-Sheet 2 #rfax/vzv/s,

Filed June 8, 1964 United States Patent() 3,253,862 WHEEL AND METHOD F MAKING THE SAME Shunso F. Watanabe, Livonia, and Ralph D. Daily, Ann,

This invention relates to vehicle wheels and, more particularly, to wheels having hollow closed spokes and/ or hubs formed by casting in a rnold provided with nonremovable cores formed of -steel wool or the like. The present invention relates to the wheel, per se,and to the method of forming the same.

Heretofore, hollow cast wheels have been manufactured in which the hollow spoke and/or hubs have been formed by cores which were removed after the wheel was molded. This necessitated the use of core removal holes or openings, the presence of which weakened the finished structure and complicated the construction of the mold and the molding operation.

It is therefore an important object of this inventionto provide a cast wheel having hollow closed spokes and/ or hub, and a method of forming such wheels, wherein the wheel has a higher strength-to-weight ratio, due to its closed construction, than presently known hollow or cored constructions provided with core removal openings.

The objects and advantages of the present invention are attained by utilizing shaped wads of steel wool or other similar material as the core members. These wads are shaped to the approximate shape of the cavities within the spokes and hub and are suspended within the mold in locations where the inner walls of the spokes and hub are to be formed. Advantageously,these core wads are located and supported by chaplets or pins protruding from the mold, which pins are preferably formed of aluminum, although -steel pins may be used. The wheel is usually cast from aluminum. When the molten metal is introduced into the mold, the interface at the juncture of the molten aluminum and the steel wool core chills sufciently to preclude penetration of the molten metal into the core. Thus, the hollow spokes and hub are formed. The steel wool cores are left in the spokes and hub, but are suiiiciently light in weight not to materiallyincrease the weight of the completed wheel.

The various objects and advantages, and the novel details of construction of one commercially practical ernbodiment of the invention, together with one approved method of forming the wheel, will become more apparent as this description proceeds especially when considered in connection with the accompanying drawings, in which:

FIGURE 1 is an elevational view of a cast wheel having an integral rim and constructed in accordance with this invention; l

FIGURE 2 is a sectional View through the wheel taken substantially on the plane indicated by line 2--2 in FIG- URE l: i

FIGURE 3 is a fragmentary sectional view through a slightly different type of wheel made in accordance with the invention, taken on line 3-3 in FIGURE 4;

FIGURE 4 is a similar section taken at right angles to FIGURE 3;

FIGURE 5 is a sectional view through a conventionaly type of mold useful in carrying out this invention; and

FIGURE 6 is a fragmentary sectional view taken substantially on the plane indicated by line 6 6 in FIG- URE 5.

It will be obvious as this description proceeds that the invention of this application may be employed with equal facility in the production of various types of integral cast hollow wheels; however, but tw o types of such wheels have been illustrated.

3,253,862 Patented May 31, 1966 In FIGURES l and 2, there is illustrated an integral rim and spider type wheel in which the reference character 10 indicates the rim and 11 the spokes of the spider. The radially inner ends of the spokes 11 terminate in or are connected to an annular hub 12 adapted for attachrnent to the rotary part 13 of an axle 14. The wheel spider is detachably secured to an annular flange 15 on the axle part 13 by means of studs or bolts 16 which pass through the ange 15 and through openings 17 formed in thickened or solid portions 18 of the wheel spider. The ends of the spokes 11 are usually formed at the inboard side thereof with -shoulders 11a adapted to rest upon the annular flange 15 of the rotary hub part 13 to center the wheel thereon. p

In the wheel shown in FIGURESl and 2, each of the spokes 11 is a completely closed hollow body forming a completely enclosed cavity 25. The hub 12, which is in open communication with the ends of the spokes 11, is also hollow and is formed with an annular cavity 26.

Wheels of the type just described have many advantages. The closed hollow portions thereof reduce the overall weight of the wheel and have a greater strengthto-weight ratio, due to the closed construction, than hollow spoked wheels formed with removable cores. The use of removable cores necessitates the use of core removal holes or openings, the presence of which weakens the finished structure. i

The present invention relates to a wheel of thisl type in which the cavities 25 and 26 are formed by lightweight nonremovable cores in a manner yet to be described.

In the form of construction illustrated in FIGURES 3 and 4, the wheel comprises a demountable rim 30 and an integral wheel spider and hub consisting of hollow spokes 31 and a hub 32 adapted to be mounted upon the axle 33. In this form of construction, each spoke comprises a completely enclosed cavity 34 extending from the hub 32 to the outer end of each spoke. The outer end of each spoke is provided with a thickened or enlarged solid portion 35. Each portion 35 is provided with an aperture 36 to receive a stud or bolt 37 by means of which the rim 30 may be secured to the wheel spider.

In this form of construction, the hub 32 is shown as being solid and the hollow spokes 31 extend radially outwardly from the solid hub portion 32 and, as stated, each spoke has a large cavity 34.

In this form of wheel, the rim 30 may be molded or may be formed by rolling, as is customary in forming rims.

The manner in which the wheels are molded to provide the hollow spokes 11 and the annular hub 12 or the hollow spokes 31 will be best understood by reference to FIGURES 5 and 6. In these figures, and particularly FIGURE 5, a conventional type mold is illustrated comprising a main flask consisting of two sections 40 secured together at their peripheries by fastening means 41. The flask sections are filled with sand 42 and the sand is shaped to form cavities 43 defining the outside contour of the rim 10 and with cavities 44 defining the outside contour of the spokes 11 and hub 12. The other side of the cavity'43 for the rim 10 is formed by flasks 45 -containing sand 46. Thus, cavities defining the shape and contour of the rim 10, spokes 11 and hub 12 are defined within the mold.

The wheel rim 10, spokes 11 and hub 12 are formed in one piece and they are preferably formed of aluminum because of its strength and lightness. Therefore, molten aluminum is introduced into the mold cavitythrough one ormore taps or sprues 47 and 48 so as to flow throughout 1 In accordance with this invention, nonremovable cores are used in the mold to define the cavities 25 or 34 of' the spokes and the cavity 26 of the hub. These nonremovable cores are preferably formed of wads 50 and 51 of metal wool, such as steel wool or the like. These masses or wads of metallic wool are firstv shaped to the approximate shape of the interior contour of the cavities 25 or 34 and the cavity 26 and' are then suspended in the mold, in the proper location, by means of pins or pin-like chaplets 52 strategically arranged to hold the preformed masses or wads in the proper location to dene the cavities in the spokes and hub. These chaplets or pins extend into the wads of metallic Wool and extend across the mold cavities into the sand in the mold sections. The wads 50 and 51 are shown as contacting one another at S0.

When the molten aluminum is poured into the taps or sprues 47 and 48 and comes in contact with these core members 50 and S1, the interface between the core members and the molten aluminum chills sufficiently to prevent penetration of the metal into the steel wool core members. Thus, the cavities 25 or 34 and 26 are formed.

Inasmuch as the spokes and hub form completely closed chambers, the core members 50 and 51 are not removable, but are left in the wheel cavities. However, due to the relative lightness of the core members, this does not materially increase the Weight of the wheel. The advantage in not removing the cores is that core removal holes or openings are not necessary, the presence of which materially weakens the wheel.

After the wheel has been removed from the mold, the protruding ends of the pins or chaplets 52 are cut off iiush with the exterior surface of the wheel, as shown,`

for instance, in FIGURE 4.

In the form of wheel illustrated in FIGURES 1, 2, and 6, the bolt openings 17 may be formed by removable core plugs 17a or these holes may be drilled after the Wheel is removed from the mold, whichever is found to be more appropriate. The openings 36 (FIGURE 3) may be formed in a similar manner.4

From the foregoing, it will be apparent that there is provided a wheel and method of forming the same wherein the wheel is provided with hollow closed spokes; and,

in one form of wheel, with a hollow closed hub. The' i metallic wool forming the nonremovable core membersV may be readily shaped to the approximate shape of the interior contour of these hollow portions and may be quickly and easily suspended in the mold at the proper locations by the strategically placed pins or chaplets 52. As stated heretofore, when the molten aluminum engages the steel wool cores, the interface between the molten aluminum and steel wool chills sufficiently to preclude any substantial penetration ofthe molten metal into the core members. When the wheel is removed from the mold, it may be quickly and easily finished by removing the protruding ends of the pins 52 and either removing the core faces 17a or by drilling the necessary holes 17 or 36. There is thereupon provided a light-weight, onepiece wheel in which'the closed hollow spokes and hub form box-like elements having a higher strength-to-weight ratio than any known hollow Wheel structures wherein removable cores are employed, necessitating the use of removal holes or openings in the wheel structure.

While two commercially practical embodiments of the invention have been described and illustrated herein somewhat in detail, it will beunderstood that various changes 4 may be made as may come within the purview of the accompanying claims.

What is claimed is:

1. A cast metal vehicle wheel provided with closed hollow portions wherein the hollow portions closely surround nonremovable cores made of masses of metallic wool.

2. A metal vehicle wheel comprising closed hollow spoke portions, and core members in said'hollow portions formed ofv nonremovable shaped wads of metallic wool.

3. A cast metal vehicle wheel comprising closed hollow portions, and nonremovable core member-sin said hollow portions formed of approximately shaped wads of steel wool.

4. A cast vehicle wheel comprising closedhollow spokes and a closed hollow hub, and nonremovable core members in said -spokes andl hub formed of shaped wads of steel wool shaped to the approximate contour of the interior of said spokes and hub.

5. In the method of forming cast metal vehicle wheels having closed hollow portions those. steps which comprise, forming a wheel pattern in a mold, forming cores for the hollow portions of the wheel by masses of metallic wool shaped approximately tothe interior contour of said hollow portions, and casting the wheel in `said mold.

6. In the method of forming cast metal vehicle wheels having c losed hollow portionsthose stepswhich comprise, formingY a wheel pattern in a mold, forming cores of approximately shaped wadsy of metallic wool, suspending said cores in the mold cavity while the wheel isbeing cast, and casting the wheel in said mold.

7. In the method o f forming cast vehicle wheels having closed hollow portions those steps which comprise, forming a wheel pattern in a mold, forming cores of metallic wool shaped to the aproximate shape of the interior contour ofy the hollow portions, supporting said cores in the mold cavity while the wheelA is being cast, and casting` the wheel in said mold. p

8. In the method of forming cast vehicle wheels having closed hollow portions those steps which comprise, forming a wheel pattern in a mold, forming cores for the.

hollow portions of wads of steel wool shaped to the approximate shape of the interior of said hollow portions,

supporting saidr cores on pin-like chaplets extending from the mold cavity, and casting the wheel in said mold.

9. A method as described in claim 8 in which the portions ofthe pin-like chaplets extending beyond the ex-` terior of the casting are trimmedv offafter the casting is removed from the mold.

References Cited by the Examiner UNITED STATES PATENTS 942,400 12;/ 1909 Montupet. 1,774,687 9/1930 Willard 301-65 X 2,084,247 6/ 1937 Dockray 22-200 2,957,214 10/1960 Kuharski 22-203 FOREIGN PATENTS 20,820 1910 Great Britain.

BENJAMIN HERSH, Primary E xamner.

A. HARRY LEVY, Examiner. y

R. J. JOHNSON, Assistant Examiner. 

1. A CAST METAL VEHICLE WHEEL PROVIDED WITH CLOSED HOLLOW PORTIONS WHEREIN THE HOLLOW PORTIONS CLOSELY SURROUND NONREMOVABLE CORES MADE OF MASSES OF METALLIC WOOL. 